Method of making sinks



May 12, 1942. v. J. GRAF' I METHOD OF MAKING SINKS Filed Sept. 20, 19377 Sheets-Sheet 1' INVENTOR Y 270627; J? Gray? (a) A TT R NE Y5? 12,1942;v. J. GRAF METHOD OF MAKING SINKS Filed Sept. 20, 19s"! 7 Sheets-Sheet 2a. m 0 T V. J. GRAF METHOD OF MAKING SINKS Filed Sept. 20, 1937 7Sheets-Sheet 3 INVENTOR 2712766275 J Grafi' 7 Sheets-Sheet 4 INVENTOR lzkycaizz 1 631 ay 12, 1942. v. .1. GRAF 2,2295% METHOD OF MAKING SINKSFiled Sept. 20, 1937 7 Sheets-Sheet 5 ay 12, 1942. v. J. GRAFII2,282,571

METHOD OF MAKING SINKS Filed Sept. 20, 1937 w 7 Sheets-Sheet 6 INVENTOR.

Myra/7i J7 qraf ATTORNEm May 12, 1942. v. J. GR-AF 2,282,571

METHOD OF MAKING SINKS Filed" Sept. 20. 1937 7 Sheets-Sheet 7 IN VENTOR.

ATTORNEYS Patented names or i ENG Vincent 5. Grad, llletroit, Mich,assignor, by

mesne Zinc, Detroit,

cats, to Steel Plbing Wares, on, a corporation n2 can ApplicationSeptember 2d, 1937, Serial No. 164,645 a @iaitns. itJi. lit--20) Thisinvention relates to sinks, washbasins and the like, and moreparticularly to the fabrication thereof by stamping operations fromsheet metal, preferably sheet steel. The present application is acontinuation in part of my co-pending applications Serial No. 663,711,filed-March 31, 1933, now Patent 2,105,944, January 18, 1938, and SerialNo. 92,803, filed July 2'], 1936, now Patent 2,127,559, August 23, 1938.v

Great difiiculties have been experienced in forming articles of theabove character, particularly' from a. single metal sheet, because ofthe necessity to form a rolledor turned rim around the basin and thedrainboarcis thereof, which rim is to merge smoothly and seamlessly intothe upright splashboard provided therein. In proximity to the juncturesof such rim with the splashboard, themetal may be overstrained andbroken in som places, while folds of excessive metal may be formed inothers which necessitates repairing such places by cutting out theexcessive metal, patching and welding the brokenplaces. This, besidescomplicating the manu- Another'obiect of the invention is to provide an.improved method of forming a sink having a basin and a. splashboardwhereby the usual cracking of the metal near the places of juncture ofthe back wall of the basin is eliminated.

It is an added object oi the invention to provide an improved method offormation of articles of the above character which method includes asmall numberbf pressing operations of a relatively simple character. c

Other objects of this invention will appear in I the followingdescription and appended claims,

reference being had to the accompanying drawing's' forming a part ofthis specification wherein like reference characters designatecorresponding parts in the several views.

' Fig. l is a perspective view of a double drain board sinkformed inaccordance with the lecturing processes, results in producing inferiorarticles, rendering it diflicult to produce an enamel finish free ofblemishes and imperiections. Preiormation of the placesof juncture ofthe turned or rolled rim with the drainboard has solved the abovedifficulties but introduced additional operations and apparatus.

One of the objects of the present invention is to provide an improvedmethod. of forming the articles of the above character from a singlemetal sheet or blank, whereby the above dimculties are overcome andlargely eliminated and a. relatively simplified and emcient method isprovided.

A further object of the invention is to provide an improved method ofmaking a sink or the like i'rom a sheet metal blank, the sink beingformed with a splash panel, a substantially flat horizontal rimextending around three sides of the basin and a substantially, flatshelf coplanar with the rim extending rearwardly of the basin and alsoFig. 7 is a. perspective view showings. metal method embodying thepresent Invention.

Fig. 2 is a transverse vertioalsectional view of the structure shown inFig. 1, looking in the directionof the arrows, section being taken alongthe line 2-2 of Fig.1.

Fig. 3 is a perspective view of a left hand drainboard sink formed inaccordance with the method embodying the invention.

Fig. 4 is a longitudinal sectional view of the structure shown in Fig.3, looking in the direction of the arrows, section being taken on theiine 6-4 of Fig. 3.

- Fig. 5 is a perspective view of a right hand drainboard sink formed inaccordance with the method embodying the invention- Fig. 6 is atransverse sectional view, of the structure shown in Fig. 5, looking inthedirection of the arrows, section being taken on the line 6-5 of Fig.5.

blank from which the sink of Fig. 1 is fabricated, with the sub-basinpreliminarily formed.

Fig. 8 is a perspective view illustrating a suc- 'ceeding step infabricating the sink, at which the the length of the sink, and in whichthe junctures of the fiat rim and the splash panel are maintainedseamless during the operations of bending up the splash panel andbending down the apron which depends from the rim. Thus, it will be seenthat no slitting and welding is necessitated at the top of the sinkwhere the fiat rim merges into the'splash panel, permitting savings inthe cost of production and greater uniformity in the attractiveappearance of sinks made in accordance with the invention.

as Fig. 12 is a. perspective view illustrating shallow'main'basin andtwo groups of beads at the bottom thereof are formed in one operation.Fig. 9 is a view taken in the direction of the arrows on the transversevertical section' through the line 9-9 of Fig. 8.

Fig. 10 is a perspective view illustrating the step of simultaneouslyforming the main basin and the drain beads in a blank for the right handsub-basin sink. i

Fig. 11 is a perspective view illustrating the operation of trimming ofthe metal blank for the sink of Fig. 1.

position of the edge before the drawing opera= tion.

Fig. 16 is a sectional view on the line id-id of s Fig. 15.

Fig. 17 is a perspective view with sections broken away illustrating theoperation of forming the wall flanges along the top and ends of thesplashback, the dotted line indicating the position of the metal beforesaid operation.

Fig. '18 is a view similar in part to Fig. 17,'illustrating theoperation of forming the bottom flange along the lower edge of thedepending apron.

. Fig. 19 shows in perspective, the sink blank after the operation ofpiercing the faucet and spout holes.

Fig. 20 is a perspective view, partly in section, illustrating a diedevice in which the blank trimming operation may be performed.

21 is a perspective view, partly in section,

illustrating a die device in which bending of the blankto form thesplashback may be performed.

Fig. 22 is a perspective view, partly in section. illustrating a diedevice in which the blank may be operated upon in order to form therearwardly extending flanges on the splashback.

Fig. 23 is a perspective view, partly in section, showing a die devicefor trimming the corners of the blank after the operation performed inthe die device illustrated in Fig. 22 is completed.

Before explaining in detail the present invention it is to be understoodthat the invention is not limited in its application to the details ofconstruction and arrangement of parts illustrated in the accompanyingdrawings, since the invention is capable of other embodiments and ofbeing practiced or carried out in various ways. it is to be understoodthat the phraseology or terminology employed herein is for the purposeof description and not of limitation, and it is not intended to limitthe invention claimed herein beyond. the requirements of the'prior art.

' In the drawings there is shown, by way of example, three sinkstructures produced in accordance with the method embodying the presentinvention. Referring particularly to Fig. 1, the same represents a'sinkor washbasin comprising. generally. a horizontally extending face 2! inwhich there "is formed amain or shallow basin 30, said: basin beingsurrounded at its four sides by said horizontal portion 20. Thelattercom- :prises-imthe finished sink a back ledge or shelf .JZI-Ffilldificontinuous rim' 22, 23, 24 merging 's'moothly'into the shelf and allforming a co- .planar horizontal surface surrounding the main andsub-basins. In the bottom of said main basin'-30 there is formed asecond basin or fluid receiving-bowl 3|, which I term the subbasin. .Itis unimportant feature of my invention, that the bottom of the mainbasin extends around all four sides of said subbasin 3|, the corresponding parts of said bottom being, indicated by the characters3211,3212, 32c and Md. The back .edge of the horizontal portion illmerges seamlessly into an upright or vertically extending splashbackindicated generally by the numeral 60. The face Bi of said splashback 40may be suitably embossed, such for example as indicated by the panelembossing (42. A desired number of suitable'iaucet and spout holes #33,43, is provided in the splashback. At its top and ends the splashboard$9 is provided with rearwardly extending flanges such as 66, t5, and 86,which iianges are in turn provided with narrow wall flanges til, t8 andd8, respectivelyisee Fig. 17). The lodge 2i which extends between themain basin 8d and the splashback is made of such width asto permit itsuse as a shelf for such articles as glasses and the like. The continuousrim portions 22, 28 and 24 which extend around the front and sides ofthe main basin 30 are preferablymade somewhat narrower" than the shelf2|. The horizontal rim portions 22, 23, 24 are turned downwardly toprovide a continuous seamless depending apron, the respective portionswhereof being designated by the numerals, 20 v and 21. The lower edgesof said apron are proa providing a double drainboard sink, with portions32a and 33b of the bottom 82 serving as drainboards. 1

The bottom 32 merges seamlessly into the walls of the sub-basin 8i,which sub-basin is made deeper than the main basin iii. The bottom it ofthe sub-basin 3i is made slightly sloping toward a drain hole 35, whichhole is preferably located not at the center of said bottom 34, butcloser to the back wall 3d of the basin. By virtue of this constructionit is possible to locate the spout outlet directly above. the drain hole85 without requiring the use of a spout of excessive length or overhangfrom the splashback to the fluid receiving bowl.

Referring to Fig. 3 there is shown in this instance a sink similar inpart to the structure of Fig. Lthe sub-basin however being arranged toprovide a so-called left hand drainboard sink. As shown inFig. 8, thesub-basin BI is arranged at the right hand side of the bottom 52 of themain basin lit, there being a narrow led e 52b between the sub-basin 5iand the right hand side wall of the mainbasin 5t, and ledges 52c and 52dformed by the bottom Ed. In other words, while in the previous structurethe portions 32a and 32!) extending at both sides of the sub-basin 3!are substantially symmetrical in the structure of Fig. 3,the drainboardportion 52a is similar to the drainboard portion 82a of the embodimentof Fig. l and is provided with beads such as 53, II. The narrow ledge52b has a width preferably 7 equal to that of the ledge 52c and ledge82d.

Referring to the embodiment illustrated in Fig. '5, the structure hereinshown is a left hand sub-basin sink differing from the structure of Fig.3 by the arrangement of the sub-basin Bl in the bottom 62 of the mainbasin. As can be clearly seen in Fig.5, the sub-basin BI is arranged atthe left hand side of said bottom 82, the narrow ledge 62a correspondingto the ledge 52b of the structure. shown in Fig. 3 while the slopingmeant portion-52b is provided with beads such as 63, 63 similar to theportion tab of the structure of Fig. 1. Horizontal ledges $20 and 52dformed as a part of the bottom 82 of the main basin 80' are locatedalong the front and the back walls of said sub-basin ti. as in theprevious embodiments the main basin extends at all four sides of the subbasin. g

Figs. 7 to 10 inclusive, illustrate preferred steps in the method offorming the sinks in accordance with the invention from a single sheetmetal blank. In fabricating the double drainboard sink of Fig. l asingle sheet metal blank it is placed in a suitable press and thecentral portion is pre-.

liminarily drawn to provide the sub-basin M, as illustrated in Fig. 7,this being accomplished by a suitably shaped die. in a succeedingoperation the blank is operated upon in suitable dies to formsimultaneously the main basin 8G and the drain beads 33 in the bottom 32thereof, as illustrated in Fig. 8. In the same or succeeding operationsthe sub-basin 3! may be re-struck and facilitating further formingoperations is given to the corners l2, l2 thereof.

The trimming operation may be performed a suitable die device, such, forinstance, as one illustrated in Fig. 20, wherein the blank operated uponis indicated by the reference character A. Referring to said figure, thedie device illustrated therein comprises a stationary die shoe 6i havingsub-dies 61a .provided with gauge brackets fill) adapted to locate theblank A in the proper operative position in the die device. The die shoe6? is provided "with cutting steels 63c coopcrating with correspondingcutting steels 58b carried by the movable punch holder 68. Springpressed members as are adapted to hold the edges of the blank A when thetrimming operation is being performed.

In some instances, it may be desirable to cut out portions of the metalat the corners 12 of the blank, as seen in Fig. 12, in order to providespace for the-flow of metal in the blank and to prevent formation offolds, or wrinkles because of the excess of marginal metal at thecorners.

In the following operation the metal in rear of the upright back wall ofthe sub-basin ii is formed or bent up along the line 14, 16 (see Fig.11) thus simultaneously forming the shelf 2| and the face di of the backpanel or splashboard Ill (see Fig. 12).-

This operation maybe performed in any suitable die device, such, forinstance, as one illustrated in Fig. 21, wherein the blank operated inga pressure pad Ila adapted to receive and support during the operationthe blank B. The movable punch holder 184s adapted to cooperate with theinsert 19 in bending the blank for producing the portion 4|.

It is an important feature of the present invention that the rearwardlyextending flanges M,

85 and 46 of the splashback i and thedependingapron portions at, 2B and31 (see Fig. 1) provided around the horizontally extending part of thesink structure and merging as indicated at ing the marginal metal of theblank in two direc- I tions, as explained in detail below.

For efiecting the formation of flanges ea, 65

and on the blank shown in Fig. 12, the marginal metal of the upstandingportion ti formed in the .preceg'operation is pressed in thedirectionperpendicular to the portion ti, as indicated by the arrows inFig. 12, substantiallyalong the dotted line id Simultaneously the face6| l5 may-be embo as at $2, slu ce embossing of the face ti requires prealso in the direction perpendicular to the splashback. These operationswhether performed separately or simultaneously may be performed in diesof various constructions. I prefer to use the die structure illustratedin Fig.22, wherein the blank designated by the character 0 is showzrinthe operative position, as it appears after the operation is completed.The die structure illustrated in said figure comprises a stationary dieshoe til to which is secured a die pad as cooperating with the punch '3"operation The die pad ti is provided with-steelinserts db and 8&3, whilethe punch 32 carries an insert ti, said inserts coming in contact withthe surfaces of the blank C and transmitting forming pressure thereto.

The result of the operation performed in the above described die deviceisillustrated in Fig. 13, wherein the splashback it is shown providedwith a continuous uninterrupted flange along its top and ends, theportion of said flange running along the top of the splash beingindicated by the numeral it, while those running along the ends of saidsplashback are indicated by it and it.

The blank having been drawn to the approximate form illustrated in Fig.13, the next step in the method preferably consists in trimming of thecorners of the splashback co in order to remove the surplus marginalmetal which might interfere with the performance of subsequentoperations. Such trimming may be accomplished in a die device such, forinstance, as one illustrated in Fig. 23, wherein the blank, indicated indotted lines, is held in an inclined position, being properly locatedwith the aid of a bracket 88. The die device illustrated in said figurecomprises a stationary die shoe 89 to which is secured a lower cuttingblade 90 cooperating with an upper cutting blade 9| secured to themovable holder 92.

Guide pins 93 are provided to ensure proper funcgo tioning of the diedevice. The die device illustrated in Fig. 23' is used for trimming thelefthand corner only, a similar die being used for trimming theright-hand cornerof the blank. I The trimming is done substantiallyalong the as heavy dotted line 94 (see Fig. .13)

After the comer trimming operation is completed, the blank has the shapeas illustrated in Fig. 1d. The next step in the method preferablyconsists in forming the depending apron flange. This is effected bypressing or turning downwardly the marginal metal of the horizontallyextending rim forming portion of the blank approximately along thedotted line 16 (see Fig. 14)

As can be seen inFig. l5 wherein-the result of this operation isillustrated, there is thus procombined or rearrangedin different order.

duced a continuous depeng apron consisting ofseamlessly merging portions2b, 28 and 211, the

warmest extremities or the portions 25 and it merging seamlessly intothe lowermost extremities of the splashboard ge portions db and d8,

respectively, such, for instance, as indicated at 28.

In many prior structures ha es corresponding to the flange it or thepresent structure, and aprons similar to the apron 2? Joined to theflange it as at as, it has been common to form both the flange db andapron 2? while the blank is still hat, or before it is bent at a rightangle, as along the line it. In accordance with such methods the flangesand aprons have been formed simultaneously by pressure in one, usually adownward direction. The integral flange so formed was thereupon slit upto the line of intended bend, and the blank bent as usual.

Thereupon triangular patches were welded into the open spacecorresponding to the locality 29 in the present structure. Seriousdisadvantages of such methods have been entirely eliminated by formingthe flange 66 and the apron 21 in sepa rate operations. As explained,the flange i6 is formed when the edges of the splashboard, already bent90 degrees with respect tothe horizontal portion of the blank, are wipedrearwardly to form flanges 64, Q5 and it. The apron 21 is formed whenthe edges of the horizontal portion of the blank are formed by wipingthe metal downward to form the apron portions 26, 26

and ti.

In addition to the foregoing steps in the formation of the sink,succeeding forming operations are desirable to provide'ilanging alongthe lower edge of the depending apron, such as shown at 28 (see Fig. 18)and providing a continuous wall flange along the rear flanged edges ofthe splashboard dd, comprised of mutually merging flange portions til,db and tit (see Fig. 1'7) r Fig. 19 shows the blank after the followingoperations of piercing and offsetting the drain hole 36, and piercingand counter-sinking the faucet and spout holes d3, 13.

In the present embodiment herein illustrated, I have set forth asequence of steps by which the method may be satisfactorily performed.The invention, however, is not limited to the sequence herein given, asobviously certain steps may be If desired, the splashboard panel and thehorizontal rim and ledge may be formed first, after which the two basinsmay be pressed out. In certain instances the drainboard may be omitted,and the steps in the method of forming such modifled structure becorrespondingly rearranged.

From the foregoing it will be seen that the sub-basin or fluid bowl ofthe sink fabricated in accordance with the method embodying theinvention is separated from the substantially flat top horizontal rim(which extends around three sides thereof) by a continuous narrow ledgeand upright shoulder forming part of the primary basin and is alsoseparated from the flat top back ledge or shelf by a correspondingnarrow ledge and shoulder, -Thls construction prevents, to aconsiderable extent, splashing of water from the fluid bowl over theflat rim. The back shelf and rim merge smoothly into one another andseamlessly into the splashback thus providing a smooth seamless surface,free of welds, which may be enamel coated satisfactorily in productionso as to be free from unsightly blemishes.

It will be clear in viewof the foregoing that aseasrr with the aid of myimproved method it is most ble to produce a sink which has an uprightsplashboard near the back wall of its sump and a rim around the same,without encountering the manufacturing difficulties which haveinvariably been experienced with the use of previous methods. It can nowbe easily appreciated that said dificultles have resulted ,chiefiy fromthe steps of bending the sheet up for formationof the splashboard alongthe upper edge of the back wall of the sump and, furthermore, along theline co-planar with the foot of the rim. Such attempts caused theformation of cracks along .13 does not depend upon the fillet or theradius of curvature in the corners between the splashback H or portion46 and the horizontal portion 2|. In addition to the direction of thedraw it depends partly upon allowing sufllcient margin in order'toprovide enough metal from which to draw. The margin illustrated in thedrawings gives good results with standard materials. In some cases itmay be desirable to provide wider margin and make the portion to in theblank of Fig. 13 somewhat wider than the same is after trimming.

In one of its broader aspects my invention contemplates providing animproved method of fabricating sinks or washbasins in accordance withwhich the blank is bent up for formation of the splashboardat a certaindistance toward the rear from the upper edge of the basin andfurthermore along a line co-planar with the top of the rim.

I claim:

1. In a method of making a sink, the steps of drawing a relatively deepbasin in a sheet metal blank while leaving substantially flat outwardlyextending rim portions of the blank around all four sides of the basinlying in substantially a single plane, bending an upwardly extendingsplash panel from one of said rim portions along a line oflsetrearwardly of the upper edge of the back wall of the basin to provide asubstantially flat shelf extending rearwardly of the basin and alsoextending the length of the sink in the common plane of said'remalningrim portions, bending down the marginal portions of said remaining rimportions to provide a substantially flat extending splash panel from oneof said rim portions along a line ofiset rearwardly of the upper edge ofthe back wall of the basin to provide a substantially flat shelfextending rearwardly of the basin and also extending the length of thesink in the common plane of said remaining rim portions, bending downthe marginal portions of said remaining-rim portions to provide a substantially flat horizontal rim and a depending apron extendingcontinuously around three sides of the basin, and maintaining the entireline of juncture between the flat rim, shelf and splash panel seamlesswhile carrying out said bending steps. e

3. In a method of making a sink, the steps of drawing a relatively deepbasin in a sheet metal blank, ofisetting the blank to provide adrainboard at an end of the basin while leaving substantially flatoutwardly extending rim portions of the blank around all four sides ofthe basin lying in substantially a single plane, bending an junctures ofthe flat rim and splash panel seamless while carrying out saidbending.steps.

4. In a method of making a .sink,'the steps of drawing a relatively deepbasin in a sheet metal upwardly extending splash panel from one of saidrim portions along aline ofiset rearwardly of the upper edge of the backwall .of the basin to provide a substantially fiat shelf extendingrearwardly of the basin and also extending the length of the sink in thecommon plane of said remaining rim portions, bending down the marginalportions of said remaining rim portions to provideea substantially fiathorizontal rim and 8. depending apron extending continuously aroundthree sides of the basin, and maintaining the blank while leavingsubstantially, fiat outwardly extending 'rlm portions of the blankaround all four sides of the basin lying in substantially a singleplane, bending an upwardly extending splash panel from one of said rimportions along a line ofiset rearwardly of the upper edge of the backwall of the basin to provide a substantially flat shelf extendingrearwardly of the basin and also extending the lengthiof the sink in thecommon plane of said remaining rim portions, flanging the marginal edgeof the splash panel and also flanging downwardly the marginal portionsof said remaining rim portions to provide a substantially flathorizontal rim around three sides of the basin, and maintaining theentire line of while carrying out said flanging steps.

VINCENT J. GRAF.

